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Tesla’s 4680 cell production process outlined in Giga Berlin’s revised filings

Credit: Tesla, Tobias Lindh/Twitter

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Tesla’s revised documents for Gigafactory Berlin have been posted online, and they are a treasure trove of information. The documents provided some new details about Tesla’s planned 4680 battery plant in Gigafactory Berlin, which Elon Musk noted is on track to be one of the world’s largest battery production facilities. They also outlined how Tesla’s 4680 cells are produced. 

While sections of the filing pertaining to the planned 4680 battery cell plant in Giga Berlin were blacked out due to sensitive information that could not be made public, the documents show some important tidbits about the upcoming facility. This includes the facility’s cell production operations over four floors, with anode and cathode production on the first floor and tabless cell production on the third floor. The battery plant is massive, requiring large foundations similar to Gigafactory Berlin’s Phase 1 zone. 

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Most importantly, Tesla also submitted a simplified diagram of its 4680 battery cell production process, though most of the diagram was blacked out in the revised filing’s public release. However, the company provided a brief overview of how its new battery cell will be produced in the upcoming facility (roughly translated through Google Translate). 

“The battery the Gigafactory Berlin requires special systems and process steps. The anodes and cathodes consist of coated current collector foils. Copper is used as the material for the anode foil and aluminum is used for the cathode foil. The anode and cathode components are manufactured in mixed processes (A020-01 and A020-02), which only use materials in powder form. The new materials used are tested and approved in our own laboratory (A020-11). 

“In order for the powder coating to adhere to the two films, they must first be pre-coated with a thin layer of adhesive (substrate) (A020-03 and A020-04). This substrate is delivered in containers. The pre-coating is necessary because a dry coating with powder takes place. After the anode and cathode components have been mixed, they are applied as a coating to the respective substrate-coated film in order to establish electrical contact (A020-05 and A020-06). The current collector foils, coated with the anode or cathode components, result in the finished anode or cathode. 

The revised filings also provided a general idea of how Tesla’s tabless cell production works. Among these is the fact that the finished 4680 cells would be subjected to 10 days’ worth of curing after their formation. 

“The anode or cathode is then cut to the required lengths with a laser in the “tabless process” (A020-08). The anode, the cathode and the separator are alternately placed one on top of the other and rolled up into a roll. This roller is then inserted into a metal housing, which is manufactured from steel rollers in a die-cutting and deep-drawing process (A020-07). In the assembly area, the final assembly and filling of the cell takes place with small amounts of electrolyte (approx. 10% of the cell weight) (A020-09). 

“The electrolyte is absorbed by the electrode coatings and enables the lithium ions to move back and forth between the anode and cathode. The housing is then closed with a lid in a welding process. The last step is the formation (A020-10) of the cell. In the formation process, the cell is electrically started up by charging and discharging it under different temperature conditions. The finished cell remains in this area for approx. 10 days and is then put to further use. The cells produced are subjected to random quality control in our own laboratory (A020-11).” 

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A link to Tesla’s filings for Gigafactory Berlin could be found here

Do you have anything to share with the Teslarati Team? We’d love to hear from you, email us at tips@teslarati.com.

Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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SpaceX to launch Starlink V2 satellites on Starship starting 2027

The update was shared by SpaceX President Gwynne Shotwell and Starlink Vice President Mike Nicolls.

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Credit: SpaceX

SpaceX is looking to start launching its next-generation Starlink V2 satellites in mid-2027 using Starship.

The update was shared by SpaceX President Gwynne Shotwell and Starlink Vice President Mike Nicolls during remarks at Mobile World Congress (MWC) in Barcelona, Spain.

“With Starship, we’ll be able to deploy the constellation very quickly,” Nicolls stated. “Our goal is to deploy a constellation capable of providing global and contiguous coverage within six months, and that’s roughly 1,200 satellites.”

Nicolls added that once Starship is operational, it will be capable of launching approximately 50 of the larger, more powerful Starlink satellites at a time, as noted in a Bloomberg News report.

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The initial deployment of roughly 1,200 next-generation satellites is intended to establish global and contiguous coverage. After that phase, SpaceX plans to continue expanding the system to reach “truly global coverage, including the polar regions,” Nicolls said.

Currently, all Starlink satellites are launched on SpaceX’s Falcon 9 rocket. The next-generation fleet will rely on Starship, which remains in development following a series of test flights in 2025. SpaceX is targeting its next Starship test flight, featuring an upgraded version of the rocket, as soon as this month.

Starlink is currently the largest satellite network in orbit, with nearly 10,000 satellites deployed. Bloomberg Intelligence estimates the business could generate approximately $9 billion in revenue for SpaceX in 2026.

Nicolls also confirmed that SpaceX is rebranding its direct-to-cell service as Starlink Mobile.

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The service currently operates with 650 satellites capable of connecting directly to smartphones and has approximately 10 million monthly active users. SpaceX expects that figure to exceed 25 million monthly active users by the end of 2026.

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Elon Musk’s xAI and X to pay off $17.5B debt in full: report

The update was shared initially in a report from Bloomberg News, which cited people reportedly familiar with the matter.

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Credit: xAI

Elon Musk’s social platform X and artificial intelligence startup xAI are reportedly preparing to repay approximately $17.5 billion in outstanding debt in full. 

The update was shared initially in a report from Bloomberg News, which cited people reportedly familiar with the matter.

Morgan Stanley, which arranged the debt financing for both companies, has reportedly informed existing lenders that X and xAI plan to pay back the full amount of the $17.5 billion debt. Bloomberg’s sources did not disclose where the capital for the repayment would be coming from.

X, formerly known as Twitter, assumed roughly $12.5 billion in debt during Musk’s acquisition of the company. xAI separately borrowed about $5 billion through bonds and loans last June. The two firms merged last year under xAI Holdings.

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Bloomberg noted that portions of the debt are relatively recent and may carry early repayment penalties. xAI’s $3 billion in high-yield bonds are expected to be redeemed at 117 cents on the dollar, reflecting a premium since the debt was expected to stay outstanding for at least two years.

X has been servicing tens of millions of dollars in monthly debt payments, while xAI has reportedly been burning approximately $1 billion in cash per month as it invests heavily in data centers, chips, and AI talent. That being said, xAI also concluded a funding round in January, where it raised $20 billion of new equity.

The repayment plans come as Musk consolidates several of his businesses. SpaceX recently acquired xAI, making it a subsidiary as the company explores plans for space-based data centers. The combined entity has been valued at approximately $1.25 trillion.

Bloomberg previously reported that SpaceX is targeting a confidential IPO filing as soon as this month, potentially positioning the private space firm for a public listing later this year. Representatives for Morgan Stanley declined to comment, and X and xAI did not immediately respond to requests for comment.

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Tesla Giga Berlin head calls out Handelsblatt’s claimed 2025 production figures

Andre Thierig, Senior Director of Manufacturing at Giga Berlin, published a detailed post on LinkedIn challenging several points made in the publication’s coverage of the Grünheide facility.

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Credit: Tesla

Tesla Gigafactory Berlin’s plant manager has publicly pushed back against recent reporting by German business publication Handelsblatt, which cited reportedly erroneous data about the factory’s production figures and financial performance.

Andre Thierig, Senior Director of Manufacturing at Giga Berlin, published a detailed post on LinkedIn challenging several points made in the publication’s coverage of the Grünheide facility.

In his LinkedIn post, Thierig called out Handelsblatt’s claim that 149,000 Model Y vehicles were produced at Giga Berlin in 2025. He noted that “the article is simply filled from front to back with false information and claims!

“I have to set the record straight here! In the last article about Tesla in Grünheide, the Handelsblatt speaks e.g. of 149,000 Model Ys built in 2025. WRONG! 

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“In 2025, we again produced over 200,000 vehicles. And this despite the fact that we stopped production in Q1 for the changeover to the new Model Y and then ramped it up again to 5,000 units per week over several weeks,” Thierig wrote. 

He added that production increased each quarter in 2025 compared to the prior quarter and stated that more than 700,000 Model Y units have been produced at Grünheide since manufacturing began in 2022. For the first quarter of 2026, he stated that the factory is planning another production increase compared to the fourth quarter of 2025.

Thierig also questioned Handelsblatt’s reported 0.74% profit margin, writing that how the publication calculated the figure “remains reserved for their secret ‘calculation skills.’”

Beyond production data, Thierig highlighted Tesla’s broader footprint in Germany, stating that the company has invested more than €5 billion in Grünheide since 2020 and created nearly 11,000 permanent, above-tariff jobs. He added that Tesla is currently investing nearly €100 million into battery cell production at the site, which is expected to generate several hundred additional positions.

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In a follow-up comment, Thierig noted that he did communicate with the publication’s editor-in-chief in an effort to “start fresh,” but he was informed that Handelsblatt’s current approach works just fine. 

“Last year, I spoke to a representative of the Handelsblatt editor-in-chief and suggested that we “start anew” again. Handelsblatt turned down this offer on the grounds that their current approach works well for them,” Thierig noted. 

Sönke Iwersen, Head of Investigative Research at Handelsblatt, responded to Thierig’s post, stating that the newspaper’s figures were based on Tesla’s own annual financial statements for the Grünheide entity.

He cited reported 2024 revenue of €7.68 billion, operating profit of €156.8 million, and net income after taxes of €55.6 million. Iwersen also referenced prior public comments from Elon Musk about Cybertruck demand, noting the gap between reported pre-orders and subsequent annual sales figures. 

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He also stated that the works council election eligibility figures Giga Berlin had dropped to 10,703 employees today from 12,415 two years ago.

“As far as production figures are concerned, these are figures from the data service provider Inovev. This is also stated in the article. Please compare this with Elon Musk’s information on demand for the Cybertruck. According to Musk, there were one million pre-orders. In the first year, 39,000 units were sold, in the second year 20,000. How can this be explained? With a million pre-orders?

“You yourself have repeatedly pointed out in recent months that no jobs would be cut in Grünheide because Tesla is different from the competition. Now a new works council is being elected in Grünheide. 10,703 people are eligible to vote. Two years ago, 12,415 people were eligible to vote. So there were exactly 1712 fewer from 2024 to 2026,” Iwersen wrote. 

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